Method of making corrugated lines box blanks



y 30, 1957 J. H. HERRICK 2,800,840

METHOD OF MAKING CORRUGATED LINED BOX BLANKS Filed July 5, 1955 2 Sheets-Sheet l Iawenfofl: Joiaa/ HHw M, 49 XW TM ,lggjbwa July 30, 1957 .J. H. HERRICK 2,

METHOD OF MAKING CORRUGATED LINED BOX BLANKS Filed July 5, 1955 2 Sheets-Sheet 2 so 30- f IIIIIII lwezzior Joizn HHea aiM a Tm M41 5? limited States Patent 1 2,800,840 METHOD OF MAKING CORRUGATED LINED BOX BLANKS John H. Herrick, Wellesley, Mass., assignor to Bestpak Inc., Natick, Mass., a corporation of Massachusetts Application July 5, 1955, Serial No. 519,687 1 Claim. (Cl. 93-36.6)

This application is a continuation-in-part of my copending application Serial No. 250,154, filed October 6, 1951, now abandoned.

The invention relates to a novel and rapid method of making foldable box blanks each having a continuous corrugated protective liner and scored on fold lines on which the blank is foldable to fully enclosed box form with the corrugated liner disposed at and forming the interior walls of the folded box, the liner thus providing a continuous protection for packaged delicate products and surfaces that would otherwise become broken or damaged. Lined folded boxes of this nature have heretofore commonly required the insertion of a separate corrugated liner, the box and liner being constructed and inserted in separate operations. The primary object of my invention resides in the continuous novel production of a scored box blank having a continuous corrugated protective liner so disposed at one face that it forms the complete and continuous interior walls of the folded box and furthermore embodies non-lined closure flap portions adapted to fold into flat surface contact with the plane exterior wall face of the box, thus producing superior corrugated lined cartons more rapidly and economically than has been heretofore possible and eliminating substantial packaging operations heretofore required.

These and other features of the invention will be best understood and appreciated from the following description of preferred embodiments thereof selected for purposes of illustration and shown in the accompanying drawings, in which- Fig. 1 is a diagrammatic view of a method of making prelined box blanks in accordance with my invention,

Fig. 2 is a plan view taken on line 22 of Fig. 1 and showing the die cut liner web,

Fig. 3 is a plan view taken on line 3-3 of Fig. 1 and showing the corrugated face of the combined liner and backing sheet webs,

Fig. 4 is an inner plan view of a completed blank, and

Fig. 5 is a perspective view of the folded box, partially broken away.

In accordance with my invention as illustrated in the drawings, the foldable blanks are constructed by combining a backing sheet web with a liner web 12. The entire operation is performed in one simple continuous feeding of the two webs together and during which the liner web is die cut to shape and then corrugated and brought into adhesive contact with the backing sheet web, the resulting composite web being thereafter severed and scored into foldable box blanks.

The liner web 12 is drawn from a roll 14 and passed between cutting die rolls 16 which pre-cut the liner web to the design required for cooperating with the backing web 10 to produce the desired prelined blanks. The pre-cut web 18, with the waste at 20 eliminated, is passed between corrugating rolls 22, the web being precut to allow for the length shrinkage of the web produced by corrugating. The bottom face of the web 18 is adhesively coated at 23 and then joined in face to face contact to the backing web 10 beneath an impression roll 24 that firmly presses the webs into adhesive contact against the adjacent corrugating roll 22. As illustrated in Fig. 1 the adhesive is applied only to the tops or apices of the corrugations where they come into contact with the backing web 10, thus conserving on the 2,800,840 Patented July 30, 1957 amount of adhesive required and leaving the corrugations of the combined webs 25 free for effecting maximum cushioning and holding protection against the packaged product.

The webs 10 and 12 are of a width to make two or more rows of blanks, two rows being illustrated at opposite sides of the broken line 27 in Figs. 2 and 3. The combined webs 25 are cut transversely at 26 into sheets 28 each containing a plurality of blanks. The sheets 28 are then die cut at 27 and along lines producing the individual blanks illustrated in Fig. 4. This operation severs each individual blank from the sheet and cuts the blank along the full lines shown in Fig. 4 and fold creases the blanks along the broken lines shown in Fig. 4. The webs can be fold creased and die cut at 26 and 27 and along said full lines in a single continuous operation if desired.

When the resulting blank shown in Fig. 4 is folded to box form (Fig. 5) the plane faced corner flaps 30 of the blank interlock at each end of the box and engage in surface contact the plane outer faces of the end walls 32 and the corrugated sheet provides a continuous protective liner 42 covering the entire inwardly facing walls of the box. The cover panel 34 folds over the bottom panel 36 and the cover tuck 38-engages within and against the end side wall 40 of the blank.

It will now be apparent that I have produced more economically and in rapid continuous operation a superior corrugated liner protective blank adapted to be conveniently folded to box form and eliminating substantial packaging operations heretofore required.

Having thus disclosed my invention what I claim as new and desire to secure by Letters Patent is:

In a method of making foldable box blanks each scored along fold lines on which the blank is adapted to fold to fully enclosed rectangular box form and each embodying a plane backing sheet having a one-piece corrugated liner adhesively affixed to one face thereof solely in the area forming the interior walls of the folded box and having predetermined marginal areas not covered by the liner and forming plane closure flap sections adapted to fold into fiat surface contact with the plane exterior wall face of the box, the steps of continuously feeding longitudinally in open width a non-corrugated liner sheet web, continuously removing from the traveling web predetermined areas of such size and location as will be disposed outside of the first named area when the web is corrugated, continuously corrugating the resulting web transversely thereof, continuously applying a coating of adhesive to the apices of the corrugations at one face of the corrugated web, continuously feeding a plane backing sheet web into face to face contact with said adhesive coated apices and over the openings left by removal of said predetermined areas, and severing the combined webs into blanks adapted to be folded into boxes with the corrugated web of each blank forming a continuous interior protective wall within the folded resulting box and with the areas of the backing sheet disposed over said openings forming plane closure flaps adapted to fold into fiat surface contact with the plane exterior wall face of the box.

References Cited in the file of this patent UNITED STATES PATENTS 1,402,259 Smith Jan. 3, 1922 1,642,782 Langston Sept. 20, 1927 1,816,321 Foss July 28, 1931 1,971,863 Lupton Aug. 28, 1934 1,983,323 Stokes Dec. 4, 1934 FOREIGN PATENTS 288,734 Great Britain Apr. 17, 1928 

